冷鐓模具設(shè)計培訓(xùn)資料

ContentsoftheTraining培訓(xùn)內(nèi)容AssemblyandsetupofCOD&COK剪刀/剪模組立Assemblyandsetupofmaindies主模組立Assemblyandsetupofpunches沖頭組立/失效分析Understandsteel&carbidetools模具組立/材料/鎢鋼Understandtoolsurface&friction模具外表/摩擦系數(shù)Understandtheeffectofpreform預(yù)成形分析10Jan2021精選pptAssemblyandsetupofCOD&COK剪刀/剪模組立精選pptAssemblyandsetupofCOD&COK1 TypesofShearing

剪切類型HalfCutterCOK/CompleteCOD半剪CompleteCOK/CompleteCOD全剪COK:CutOffKnife

剪刀COD:CutOffDie

剪體精選pptAssemblyandsetupofCOD&COKBasicMechanismofShearing剪切根底知識WhatHappenDuringShearing:-剪切過程產(chǎn)生：ElasticDeformation彈性變形Roll-over曲面Plasticshear塑性剪切InitialFracture初始斷裂FinalFracture最終斷裂PhysicalSeparation實際剪斷精選pptAssemblyandsetupofCOD&COK2 BasicMechanismofShearingQualityProblems:-質(zhì)量問題OvalShape

橢圓形Tilting

歪斜Poorshear

剪切面粗糙Burr

毛刺NotStraight不直ClearanceTooBig間隙太大OptimumClearance最正確間隙ClearanceTooSmall間隙太小ElasticDeformation彈性變形Roll-over曲面Plasticshear塑性剪切InitialFracture初始斷裂FinalFracture最終斷裂PhysicalSeparation實際剪斷精選pptAssemblyandsetupofCOD&COK2 BasicMechanismofShearing(HalfCutCOK)半剪NoControlofBlank 落料無法控制DifferentShearPatterns 剪切方式不同BlankNotStraight 線材不直BigRoll-over 曲面較大LowCost 本錢低廉EasytoSetup 安裝簡易LongToolLife 模具壽命較長精選pptAssemblyandsetupofCOD&COK2 BasicMechanismofShearingNeedReliefSurfaces 需要外表退讓〔退剪槽〕CarefulControlofClearance 間隙要求高DifficultCOK/CODAlignment 剪刀、剪體對齊困難BetterShear/Quality 較好的剪切質(zhì)量AchieveStraightBlank 剪斷的線材較直SmallRoll-over 曲面小(CompleteCut全剪)精選pptAssemblyandsetupofCOD&COKCommonBlankQualityIssue

常見的線材剪切質(zhì)量問題Roll-over

曲面Plasticshear

塑性剪切SecondaryFracture/Tongue

二次斷裂/舌狀毛刺Burr

毛刺Straightness

直線性1443234精選pptAssemblyandsetupofCOD&COK4 COD&COKSetting

安裝Relief外表退讓〔退剪槽〕SmallRadius小圓角Relief外表退讓〔退剪槽〕精選pptAssemblyandsetupofCOD&COK5 COD&COKMaterials材料ToolSteel模具鋼Carbide鎢鋼精選pptAssemblyandsetupofCOD&COK6

MainProcessParameters主要參數(shù)MaterialHardness

材料硬度COK/CODClearance剪刀/剪體間隙COK/CODDiameters剪刀/剪體內(nèi)孔直徑COKSpeed

剪刀速度Lubricants

潤滑TypesofCOK

剪刀類型Hardermaterialsneedbiggerclearance,moretoolrelief&higherspeed當(dāng)剪切較硬的線材時,需要更多的間隙,外表退讓(退剪槽)和更快的速度.TooloosetheCOD/COKdiameterswillbendtheblankandcausetaperends剪刀/剪體的內(nèi)孔直徑太大時,會造成線材彎曲,線材末端縮小.Shearingwithoutlubricantscausesshorttoollife無潤滑剪切會縮短模具壽命.精選pptAssemblyandsetupofCOD&COK7 UnderstandDefects缺陷分析?PoorShearedSurface:smallclearanceandnotoolrelief 剪切面粗糙:間隙太小/沒有外表退讓Burr:COKor/andCODwornoff 毛刺:剪刀/剪體磨損Tongue:smallclearanceandnotoolrelief 舌狀毛刺:間隙太小/沒有外表退讓BentBlank:COK/CODdiametertoobig 線材彎曲:剪刀/剪體內(nèi)孔直徑太大OvalShape:COK/CODdiametertoobig 橢圓形:剪刀/剪體內(nèi)孔直徑太大BigRoll-over:clearancetoobigandToolwornoff 曲面大:間隙太小/模具磨損精選pptAssemblyandsetupofCOD&COK7 UnderstandDefects缺陷分析?硬材料間隙較小剪切面較好刀口易磨損鎢鋼易破損軟材料間隙較大剪切面難控制要退讓曹材料易彎精選pptAssemblyandsetupofmaindies主模組立精選pptAssemblyandsetupofmaindiesBasicofColdForming 冷鍛的根底知識MaterialsforDieConstruction 模具的材質(zhì)TypesofDieDesign 模具設(shè)計的類型ImportanceofDieSurfaceFinishing 模具外表加工的重要性CompressiveStress 壓應(yīng)力GoodDieAssembly 正確安裝模具DefectiveParts/PoorDie 缺陷部件/劣質(zhì)模具

精選pptAssemblyandsetupofmaindiesBasicofColdForming正擠壓反擠壓打頭精選pptAssemblyandsetupofmaindiesBasicofColdFormingAcombinationofdiscipline,skill,knowledge&continuousimprovement.生產(chǎn)良好的冷鍛件，操作者需要具備:紀律,技能,知識和持之以恒的進取精神。冷鍛的根底知識精選pptAssemblyandsetupofmaindiesMaterialsforDieConstruction模具的材質(zhì)

CarbideInsert鎢鋼HotWorkSteel耐熱鋼HighSpeedSteel高速鋼精選pptAssemblyandsetupofmaindiesTypesofDieDesign模具設(shè)計的類型SolidMainDie實心主模StepSolidMainDie臺階實心主模

Die-Piece/Casing/Insert套片整裝主模StepDie-Piece/Casing/Insert臺階套片整裝主模精選pptAssemblyandsetupofmaindiesTypesofDieDesign模具設(shè)計的類型LowCost本錢低廉EasyAssemble組裝簡易LongToolLife模具壽命長久TheREASONfordifferentdiedesigns不同模具設(shè)計的成因NormalCost本錢一般EasyAssemble組裝簡易ToolLifeShorter模具壽命較短SomeAssemblyProblem某些組裝問題DifficulttoAlignment對齊困難ShortDie-pieceLife套片壽命短HighCost本錢昂貴SomeAssemblyProblem某些組裝問題DifficulttoAlignment對齊困難ShortDie-pieceLife套片壽命短VeryHighCost本錢最昂貴精選pptAssemblyandsetupofmaindiesImportanceofDieSurfaceFinishing 模具外表加工的重要性Grindingmarkspromotecracks 模具研磨紋路造成脆裂Roughsurfacespromotegalling 粗糙的外表造成外表磨傷PoorinternalsurfacecausesshortKOPlife 粗糙的內(nèi)孔面縮短頂針使用壽命Sharpradiuscausesdiechip&fracture 模具尖角太鋒利造成模具脆裂或破損精選pptAssemblyandsetupofmaindiesCompressiveStress壓應(yīng)力Propercompressivestresstoreducematerialbreathingduringforming

適當(dāng)?shù)膲毫蓽p少在冷鍛時材料的伸展Increaseproductdimensionstability

增加產(chǎn)品尺寸的穩(wěn)定性Extendtoollife

延長模具壽命0.5%hot-shrink-fitinterference0.5%預(yù)熱組合的過盈配合量0.5%coldpressinterference0.5%冷裝組合過盈配合量0.5%taperpressinterference0.5%斜角局部的過盈配合量精選pptAssemblyandsetupofmaindiesGoodDieAssembly正確組裝模具Positivesteptoensurepropersupportofdiepiecebydieinsert有效間隙以保證給予套片適當(dāng)?shù)闹蜳ositivesteptoensurepropersupportofdieinsert有效臺階以保證給予組合套心適當(dāng)?shù)闹蜸ufficientchamferProperinstallationofdiepiece適當(dāng)安裝套片SufficientInterference足夠的過盈量足夠的倒角精選pptAssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具DiePieceBreaks:套片破裂1 Diepieceanddiecaseoffcenters 套片和主模套偏心2 Roughsurfaces/insufficientpolishing 外表粗糙/研磨,拋光缺乏3 Poormatchingoftapersurfaces 斜角局部配合不好4 Insufficientcompressivestress 壓力缺乏5 Nopropersupportfromdieinsert 組合套心沒有給予套片恰當(dāng)?shù)闹? Insufficientstepradius 臺階局部圓角太小7 Poorpunch/diealignment 沖件/主模沒有對齊8 Blankover-length 線材剪切太長9 PunchRecesshitting 二沖竄傷10 HighKOforce(taper/overforged/roughsurface) 頂出力太大(倒錐，太飽滿，外表粗糙〕精選pptAssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具StepDieFractures:臺階主模破損Hydrauliceffect/toomuchoil/air&oiltrap 液壓影響/潤滑油太多/憋氣憋油Insufficientstepradius 臺階局部圓角太小Roughsurfaces/insufficientpolishing 外表粗糙/研磨,拋光缺乏Poorpunch/diealignment 沖件/主模沒有對齊Blankover-length 線材剪切太長Poorhot-shrink-fit 預(yù)熱組裝配合差Heavyknockoutaction 頂針沖擊力過大PunchRecesshitting 二沖竄傷HighKOforce(taper/overforged/roughsurface)頂出力太大(倒錐，太飽滿，外表粗糙〕精選pptAssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具MainDieChipoff/Cracks:主模脆裂Impropersittingofmaindie 主模安裝位置不正確Insufficientstepradius 臺階局部圓角太小Roughsurfaces/insufficientpolishing 外表粗糙/研磨,拋光缺乏Poorpunch/diealignment 沖件/主模沒有對齊Blankover-length 線材剪切太長Poorhot-shrink-fit 預(yù)熱組裝配合不好Overknockoutaction 頂針行程過大PunchRecesshitting 二沖竄傷精選pptAssemblyandsetupofmaindiesDefectiveParts/PoorDies 缺陷部件/劣質(zhì)模具Diewear:模具磨損Poorhot-shrink-fit預(yù)熱組裝配合不好Poorpunch/part/diealignment沖件/沖頭/主模沒有對齊Wrongcarbidegrades選擇錯誤的鎢鋼等級Insufficientorwronglubricant潤滑缺乏或用錯潤滑油PartsDefects:部件缺陷Gallingduetomisalignment/poorcarbide磨傷--模具沒有對齊/劣質(zhì)鎢鋼Blankdiameteroversizeduetopoorhot-shrinkfit光桿直徑太大--預(yù)熱組裝配合差Blankdiameterundersizeduetowrongdiediameter光桿直徑太小--主模內(nèi)徑錯誤Inconsistentblankdiameterduetodiediametertoobig光桿直徑不穩(wěn)定--主模內(nèi)徑太大Roughsurfacesduetopoordiepolishing外表粗糙--模具研磨,拋光缺乏精選pptAssemblyandsetupofpunches沖頭組立/失效分析精選pptTiming/Speed時間/速度Friction摩擦系數(shù)Alignment對齊HowPunchesFail二沖如何損壞CommonPunchProblems常見二沖問題CommonProductProblems常見產(chǎn)品問題

精選pptTiming/Speed時間/速度4m/sec(4米/秒)1m/sec(1米/秒)(MH-10Machine)(UI-10Machine)精選pptFriction摩擦系數(shù)ToolDimension(cancheck)模具尺寸(可以測量)ToolSurfaceRoughness(difficulttocheck)模具外表粗糙度(較難測量)精選pptFriction摩擦系數(shù)ChangingFactors:-影響因素LubricationOil潤滑油ToolSurfaceRoughness模具粗糙度PreformSetting一沖成形設(shè)置MachineSpeed機器速度ChangingDimension:-受影響尺寸Flatness平直度HeadCornerRadii頭部圓角HeadRoundness頭部圓度Headdiameter頭部直徑精選pptAlignment對齊PrematureWearofRecessIncorrectHeadShapePrematureBreakofRecessOff-centerRecess(<0.05mm

)梅花局部磨損頭形錯誤梅花局部破裂梅花偏心(<0.05mm)精選pptHowPunchesFail1.WearoffIncorrectHardness(AboveHRC65)InsufficientLubricantIncorrectPunchMaterial(M2,M42,Carbide)WithoutCoating(TiN,TiCN,TiAlN)PoorPreform(1stPunchPreparation)NatureWear2.ChipOffPoorAlignmentPoorSetupSkillPoorsurfaceIncorrectPunchMaterialMishandlingVibrationSpeedtooFast3.BreakoffRecessStrippedoffbending/MisalignmentPinandInsertMismatchIncorrectPreform(1stPunchPreparation)SpeedtooFastWrong/InstableProcessHighFrictionPoorCutOff1121233精選ppt二沖如何損壞1.磨損硬度錯誤(高于HRC65)潤滑缺乏二沖材質(zhì)錯誤(M2,M42,Carbide)沒有涂層(TiN,TiCN,TiAlN)一沖成形差(1stPunchPreparation)自然磨損2.破損沒有對齊安裝技術(shù)差外表粗糙二沖材質(zhì)錯誤人為損壞震動機器速度太快3.斷裂梅花破裂二沖棒彎曲/沒有對齊二沖套和沖棒不配一沖成形錯誤(1stPunchPreparation)速度太快錯誤/不穩(wěn)定生產(chǎn)程序摩擦系數(shù)太大線材剪斷不良1121233精選pptCommonPunchProblemsShortToolLifeIncorrectHardness(AboveHRC65

)InsufficientLubricantIncorrectPunchMaterial(M2,M42,Carbide)WithoutCoating(TiN,TiCN,TiAlN)PoorPreform(1stPunchPreparation)PoorAlignmentPoorSetupSkillPunchMaterialtooHard(AboveHRC68

)MishandlingVibrationSpeedtooFastWrong/InstableProcessHighFrictionDimensionoutPoorToolSuppliersPoorReworkToolingnotmatchOrderWrongToolPoorToolSuppliers精選ppt常見二沖問題壽命短硬度錯誤(高于HRC65)潤滑缺乏二沖材質(zhì)錯誤(M2,M42,Carbide)沒有涂層(TiN,TiCN,TiAlN)一沖成形問題(1stPunchPreparation)沒有對齊安裝技術(shù)差二沖材質(zhì)太硬(高于HRC68)人為損壞震動機器速度太快錯誤/不穩(wěn)定生產(chǎn)程序摩擦系數(shù)太大尺寸錯誤模具供給商不佳模具修改誤差模具不能配合購置錯誤模具模具供給商不佳精選pptCommonProductProblems常見產(chǎn)品問題IncorrectRecessProfileLubricationOilToolSurfaceRoughnessIncorrectToolDimensionIncorrectRecessDepthRecessWearRecessChipoffRecessOff-setPoorPunchAlignmentPoorPreformPoorCutoffBigChamferLubricationOilIncorrectToolDimensionIncorrectPreformUnusualVisualDefectsLubricationOilToolSurfaceRoughnessIncorrectToolDimension成形形狀不正確潤滑油模具外表粗糙度模具尺寸不正確成形深度不正確沖棒磨損沖棒破損成形偏心二沖沒有對齊一沖成形差線材剪斷不良斜角大潤滑油模具尺寸不正確一沖成形不正確非正常的外觀缺陷潤滑油模具外表粗糙度模具尺寸不正確精選ppt4.Understandsteel&carbidetools精選pptManufacturingofFastenersandforgingpartsfallinthesamefamily緊固件與冷鍛件的生產(chǎn)工藝精選pptLowcarbonsteelAnti-gallingSUS

高耐磨不銹鋼Hotworksteel

耐熱鋼Generaltoolsteel

普通工具鋼Highspeedsteel

高速鋼Coarsegraincarbide

粗顆粒鎢鋼Finegraincarbide

細顆粒鎢鋼300SUS400SUS4000Mpa兆帕3000MPa2000MPa1000MPaHowStrongisStrong鋼的強度對照表1000Mpa=100kg/mm21000

兆帕=100千克/毫米2低炭鋼300系列不銹鋼400系列不銹鋼精選pptDieDesign模具設(shè)計螺紋鎖緊件套殼上套心下套心鎢鋼套心襯套給予軸向預(yù)先加壓精選ppt123GoodDieAssembly正確組裝模具預(yù)先加壓卸載加載精選pptphase1cyclicloading

oftheundamagedmaterial材料受力而產(chǎn)生反復(fù)的脹縮變形phase2initiationof

microcracks

a<0.1mm開始出現(xiàn)微小的裂痕phase3mergingofmicrocrackstosurfacedefectsandlargercracks

0.1<a<0.5mm微小的裂痕深入到外表，使裂紋加深phase4growthoflargercracks

a>0.5mm演變成更大的裂痕CarbideInsert鎢鋼HotWorkSteel耐熱鋼HighSpeedSteel高速鋼精選ppt5.Understandtoolsurface&friction精選pptUnderstandtoolsurface&friction理解模具外表及摩擦力Whatisfriction什么是摩擦力?Effectoffriction摩擦力產(chǎn)生的影響?Practicalconsiderations應(yīng)用時需考慮的因素?精選pptWhatisfriction什么是摩擦力?YForce拉力XForce壓力FrictionCoefficientm=Xforce/Yforce摩擦系數(shù)m=X壓力/Y拉力NormalFrictionCoefficientformetalforming=0.05to0.2通常金屬外表磨擦系數(shù)=0.05to0.2精選pptEffectoffriction摩擦力產(chǎn)生的因素AssumeHighToolFriction采用摩擦力大的模具AssumeLowToolFriction采用摩擦力小的模具精選pptEffectoffriction摩擦系數(shù)產(chǎn)生的影響?AssumeLowToolFriction采用摩擦力小的模具AssumeLowToolFriction采用摩擦力小的模具精選pptEffectoffriction摩擦系數(shù)所產(chǎn)生的影響AssumeLowToolFriction摩擦力那一邊大??？?精選pptPracticalconsiderations實際情況需考慮因素??精選pptPracticalconsiderations實際情況考慮因素精選pptUnderstandtheeffectofpreform了解預(yù)成型的影響精選pptUnderstandtheeffectofpreform了解預(yù)成型的影響WhatisPreform什么是預(yù)成型Whatisanoptimisedpreform什么是好的預(yù)成型Theeffectofpreform預(yù)成型的影響Whatisanoptimisedprocesscontrol什么是好的預(yù)成型過程控制Canpreformbealwaysbethesame預(yù)成型都是相同的嗎?Shouldwehaveapreformdrawing我們需要預(yù)成型圖紙嗎精選pptWhatisPreform什么是預(yù)成型?精選pptWhatisanoptimisedpreform什么是好的預(yù)成型?Operational:-操作方面?ToolLife:-模具壽命方面?ProductQuality:-產(chǎn)品質(zhì)量方面?精選pptWhatisanoptimisedpreform什么是好的預(yù)成型Operational:-操作方面Controllable可控制的Achievable能夠完成的Stable穩(wěn)定的Maintainable可持續(xù)的Lowcost低本錢的Manufacturable可操作的Repeatable可重復(fù)的Independent不受制約的ToolLife:-模具壽命方面Lowpunchforce低沖力Lowpunchstress低壓力Manufacturable可持續(xù)的Lowcost低本錢的ProlongOperation延長生產(chǎn)力ProductQuality:-產(chǎn)品質(zhì)量方面No/MinimumDefects無缺陷或缺陷最小Achieveconsistentquality到達品質(zhì)一致Achieverequireddimension到達要求尺寸精選pptTheeffectofpreform預(yù)成型的影響Operational:-操作方面Controllable可控制的Achievable可實現(xiàn)的Stable穩(wěn)定的Maintainable可持續(xù)的Lowcost低本錢的Manufacturable可操作的Repeatable可重復(fù)的Independent不受約束的ToolLife:-模具壽命Lowpunchforce低沖力Lowpunchstress低壓力Manufacturable可操作Lowcost低本錢ProlongOperation延長生產(chǎn)力ProductQuality:-產(chǎn)品質(zhì)量No/MinimumDefects無/最小缺陷Achieveconsistentquality到達質(zhì)量一致Achieverequireddimension到達要求尺寸Punchforce沖力Punchstress壓力Toolwear模具磨損Laps/Folds褶皺Surface外表條件Dimensions尺寸Toollife模具壽命Partquality部品質(zhì)量精選pptTheeffectofpreform預(yù)成型的影響Test1:-試驗1WidePunchChamferAngle沖模倒角較大Test2:-試驗2SmallPunchChamferAngle沖模倒角較小FormingoffastenersusingdifferentPreformdesign(effectofpreformonthefinalformingshape)采用不同預(yù)成型的產(chǎn)品的最后成型Using5113forIllustration以5113為例矮扁的預(yù)成形較高的預(yù)成形精選pptTheeffectofpreform預(yù)成型的影響Higherformingpressure較高的成型壓力Lowerformingpressure較低的成型壓力Fastenerformingusingflatterpreform采用扁而平的預(yù)成型Fastenerformingusingtallerpreform采用較高的預(yù)成型矮扁的預(yù)成形較高的預(yù)成形精選pptTheeffectofpreform預(yù)成型的影響Tallerpreform高預(yù)成型Lowpunchforce沖力小Longertoollife模具壽命長Stableprocess過程穩(wěn)定